ESAB PRB 36-80 User manual

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SAFETY 2..............................................

TECHNICAL DESCRIPTION 3.............................

INSTALLATION 5........................................

OPERATION 7..........................................

MAINTENANCE 9........................................

SICHERHEIT 11..........................................

TECHNISCHE BESCHREIBUNG 12.........................

INSTALLATION 14........................................

BETRIEB 16..............................................

WARTUNG 18............................................

SÉCURITÉ 20............................................

DESCRIPTION TECHNIQUE 21............................

INSTALLATION 23........................................

MISE EN MARCHE 25.....................................

ENTRETIEN 27...........................................

VEILIGHEID 29...........................................

TECHNISCHE BESCHRIJVING 30..........................

INSTALLATIE 32..........................................

GEBRUIK 34.............................................

ONDERHOUD 36.........................................

DIMENSION DRAWING -- MASSBILD --

COTES D’ENCOMBREMENT -- MAATSCHETS 38......

DIAGRAM -- SCHALTPLAN -- SCHÉMA -- SCHEMA 40........

WEAR COMPONENTS - VERSCHLEISSTEILE -

PIÈCES D’USURE - SLIJTAGEONDERDELEN 48......

Rights reserved to alter specifications without notice.

Änderungen vorbehalten.

Sous réserve de modifications sans avis préalable.

Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.

-- 1 --mmvarnea

WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR

EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANU--

FACTURER’S HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet g loves or

wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.

S Use ventilation, extraction at the arc, or both, to keep fumes and gases from

your breathing zone and the general area.

ARC RAYS -- Can injure eyes and burn skin

S Protect your eyes and body. Use the correct welding screen and filter lens

and wear protective clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no

inflammable materials nearby.

NOISE -- Excessive no ise can damage hearing

S Protect your ears. Use ear defenders or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION

S Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE OPERATING MANUAL

BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

SAFETY

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SAFETY

Users of ESAB welding equipment have u ltim ate responsibility for ensuring that any-

one who works on or near the equipment observes all the relevant safety precau-

tions.

Safety precautions must meet the requirements that apply to this type of welding

equipment.

The following recommendations should be observed in addition to the standard re-

gulations that apply to the work place.

All work must be carr ied out by tr ained personnel who are familiar with the operation

of the welding equipment.

Incorrect operation of the equipment may lead to a hazardous situation which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:

S its operation

S the location of emergency stops

S its function

S relevant safety precautions

S welding

To make this easier each switch, pushbutton or potentiometer is marked with a

symbol or text that indicates its function when activated.

2. The operator must ensure that:

S no unauthorized person is stationed within the working area of the equipment

when it is started up.

S that no--one is unprotected when the arc is struck

3. The work place must:

S be suitable for the purpose

S be free from draughts

4. Personal safety equipment

S Alwa ys wear recommended personal safety equipment, such as safety

glasses, flame--proof clothing, safety gloves.

S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified

electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close

at hand.

S Lubrication and maintenance must not be carried out on the equipment dur-

ing its operation.

TECHNICAL DESCRIPTION

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TECHNICAL DESCRIPTION

Pipe welding tool A21 PRB is designed for TIG welding of pipe joints.

The pipe welding tool is water--cooled and designed for use with standard ESAB TIG

welding equipment -- PROTIG 315 and MECHTIG 315. If filler wire is required the

MEI 20 wir e feed unit can be used.

Technical data

Pipe welding tool PRB 18--40 PRB 36--80 PRB 71--160 PRB 140--220

Order number 332 912--880 332 913--880 332 914--880 332 915--880

Pipe. external diameter 18--40 36--80 71--160 140--220

Rotation speed (rpm) 0.15 -- 2.3 0.1, -- 1.3 0.04 -- 0.62 0.03 -- 0.57

Max. welding current at 100% duty

cycle

250 250 250 250

Electrode diameter (mm) 1.6 (2.4) 2.4 (1.6) 2.4 (1.6) 2.4 (1.6)

Weight excl. connecting cable 2.2 kg 4.1 kg 11.5 kg 15 kg

Dimension drawing See on page

38

See on page

38

See on page

39

See on page

39

Drive unit

Motor rotor voltage, max.

Motor rotor current, max.

Motor speed at 20 V

24 V DC

0.5 A DC

3000 v/min

Continuous A--weighted noise level 58 db

Tachometer generator voltage 1,8 V

Gear ratio 91.12:1

Filler wire diameter 0.6 , 0.8

dsa2d001

The pipe welding tool is designed according to a special clamping principle that al-

lows quick and accurate positioning on the pipe. A pair of jaws ( 1) lock the pipe weld-

ing tool onto the pipe when the locking lever (2) is pressed against the handle. Dur-

ing welding the only part that rotates is the gear ring (3).

TECHNICAL DESCRIPTION

-- 4 --

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Rotation is provided by a drive unit (4) consisting of a permanently magnetised DC

motor, which is supplied with current from the control equipment, and a tachometer

generator, which generates a voltage that is proportional to the speed of the DC

motor. This voltage is fed back to the control equipment.

INSTALLATION

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INSTALLATION

General

1. MECHT IG 315, see operating manual 443 420.

2. PROTIG 315, see operating manual 443 419.

3. Wire feed unit MEI 20 see operating manual 443 421.

dsa2i002

4. Secure the connecting cable to the hose support (6) and hose guide (7) to pre-

vent it being burnt by the pipe.

dsa2i003

5. If required, install the wire conduit and contact tip supplied (9). Adjust the posi-

tion of the filler wire in relation to the electrode using an Allen key.

6. Screw the gas lens onto the electrode holder (9) using an Allen key.

7. For dimensions, see on page 38.

8. For diagram, see on page 40.

Reducing the width of the pipe welding tool for welding in restricted

spaces.

PRB 18--40

S Remove one of the hose supports (6).

NOTE!Do not remove the hose support (6) that secures the power/water cable.

S Replace the adjuster bolt (5) by an M5 Allen screw.

INSTALLATION

-- 6 --

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PRB 36--80, 71--160 och 140,220

S Remove the hose guide (7).

S Replace the adjuster bolt (5) by an Allen screw.

WARNING!

Rotating parts can cause injury, take great care.

OPERATION

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OPERATION

dsa2o001

1. Set the correct pipe diameter using the knob (2) while holding the locking lever

(4) closed.

2. Open the pipe welding tool by releasing the locking lever (4).

3. Turn the knob (2) a further 1/4 turn to take up any play.

4. Lock the pipe welding tool on the pipe using the locking lever (4).

5.

dsa2i003

Open the release lever (3) on the tool.

6. Turn the gear ring (8) about 1.5 turns, to wind up the connecting cable. The pipe

welding tool is now ready for welding.

7.

dsa2i002

Adjust the electrode height using an Allen key.

OPERATION

-- 8 --

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8. Adjust the transverse position of the electrode using the axial adjustment screw

(5).

9. Set the welding parameters (see programming manual for PROTIG 443 425)

10. Open the locking lever on the tool (4) once welding is complete.

11. Also see the programming manual for PROTIG 315, order no. 443 425 and the

operating manual for MECHTIG 315, order no. 455 381--001.

MAINTENANCE

-- 9 --dsa2m1ea

MAINTENANCE

Daily

1. Check that all cables and hoses are free from damage.

2. Clean the pipe welding tool.

If necessary

1. Lubricate all sliding surfaces with Molykote G Rapid Paste.

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-- 4 1 --dsa2e1 1a

DIAGRAM -- SCHALTPLAN -- SCHÉMA -- SCHEMA

PROTIG 315 -- PRB 18--220

Designation Bezeichnung Désignation Omschrijving

A PRB Tube welding tool PRB Rohrschweisswerk-

zeug

PRB Outil de soudage de

tubes

PRB--gereedschap

B Programming unit Programmiereinheit Unité de programmation Programmeerunit

C Remote control, start/stop Fernsteuerung, Start/

Stopp

Commande à distance,

marche/arrêt

Afstandsbediening start/

stop

D PROTIG front connection PROTIG Frontan--

schluss

PROTIG connexion fronta-

le

PROTIG frontaan--

sluiting

E PROTIG rear connection PROTIG Anschluss hinten PROTIG connexion arrière PROTIG--achteraan--

sluiting

G Wire feed unit

MEI 20

Drahtvorschubeinheit

MEI 20

Dévidoir

MEI 20

Draadvoedingsunit

MEI 20

H Emergency stop Notaus Arrêt d’urgence Noodstop

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-- 4 5 --dsa2e1 1a

DIAGRAM -- SCHALTPLAN -- SCHÉMA -- SCHEMA

MECHT IG 315 -- PRB 18--220

Designation Bezeichnung Désignation Omschrijving

A PRB Tube welding tool PRB Rohrschweisswerk-

zeug

PRB Outil de soudage de

tubes

PRB--gereedschap

B Programming unit Programmiereinheit Unité de programmation Programmeerunit

C MECHTIG front connec-

tion

MECHTIG Front--

anschluss

MECHTIG connexion fron-

tale

MECHTIG--frontaan--

sluiting

D MECHTIG rear connection MECHTIG Anschluss hin-

ten

MECHTIG connexion ar-

rière

MECHTIG--achteraan--

sluiting

G Wire feed unit

MEI 20

Drahtvorschubeinheit MEI

20

Dévidoir

MEI 20

Draadvoedingsunit

MEI 20

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ESAB Welding Equipment AB

SE--695 81 LAXÅ

SWEDEN

Phone +46 584 81 000

Fax +46 584 123 08

www.esab.com

000930

ESAB subsidiaries and representative offices

Europe

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Tel: +43 1 888 25 11

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Tel: +32 2 745 11 00

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Tel: +420 2 819 40 885

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